KR20090013768A - Process for the preparation of large scale conjugates using reactive multilayer connections - Google Patents

Abstract

The component body of material over a large bond area by placing a plurality of substantially contiguous sheets of reactive composite material 12 between the component bodies and adjacent sheets of fusible material 14A, 14B. A method of connecting 10A, 10B is disclosed. The contiguous sheets 12 of the reactive composite material may be selectively connected by a ignitable crosslinking material 22 such that an ignition reaction in one sheet 12 may cause an ignition reaction in another. Make sure The application of a uniform pressure and the ignition of one or more of the contiguous sheets 12 of the reactive composite material causes an exothermic reaction that develops through the bonding region, resulting in any adjacent sheets of fusible material 14A, 14B. Fusion and a bond was formed between the component bodies 10A, 10B.

Description

METHODS FOR FABRICATING LARGE DIMENSION BONDS USING REACTIVE MULTILAYER JOINING}

Cross Reference of Related Applications

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Declaration on Federally Sponsored Research

The United States Federal Government has certain rights in the invention in accordance with NSF Award DMI-034973.

Field of technology

The present invention is directed to connecting powders of material on large scale bonding regions using reactive composite materials such as reactive multilayer foils and the like.

Reactive composite joining, as shown in US Pat. Nos. 6,534,194 B2 and 6,736,942 to Weis and his colleagues, solders, welds or solders materials at room temperature. Brazing is a particularly advantageous process below. The process involves embedding a reactive composite material (RCM) between two layers of fusible material. Subsequently, the reactive composite material and the fusible material are positioned between two components to be connected and ignited. A self propagating reaction is initiated in the reactive composite, resulting in a sharp rise in temperature in the reactive composite. The heat released by the reaction melts adjacent layers of fusible material and by cooling the fusible material bonds the two components together.

Alternatively, depending on the composition of the two components, no layers of fusible material are used and the reactive composite material is located directly between the two components. The thermal energy released by the ignition of the reactive composite material melts the material from the surfaces of adjacent ureters and subsequently connects the components.

Referring to FIG. 1, a batch 9 is depicted for carrying out the process of reactive complex linking of two components 10A and 10B. Sheets or layers of reactive composite material 12 are located between two sheets or layers of fusible materials 14A, 14B and in turn are mating surfaces (not shown) of the components 10A, 10B. Are embedded between them. Subsequently the embedded assemblies are pressed against each other as represented by a vise 16 and the reactive composite material is ignited as represented by the match 18. The reaction rapidly develops through the reactive composite material 12 to melt the fusible layers 14A and 14B. The molten layers cool and connect the components 10A and 10B to each other. The reactive composite material 12 is typically a reactive multilayer thin film, and the fusible materials 14A and 14B are typically solder or brass.

The connection process of the two components 10A, 10B occurs faster for the reactive composite connection process than for conventional connection techniques such as utilizing furnaces or torches. Thus, a clear gain in productivity can be achieved. In addition, by highly localized heating in connection with the reactive composite coupling process, temperature sensitive components, like dissimilar materials such as metals and ceramics, can be soldered or soldered without thermal damage. Fine-grained metals can be soldered or soldered together without grain growth, and coarse bulk amorphous materials can only be local excursions from room temperature. ) Can be welded together to form high strength bonds while minimizing crystallization.

The reactive composite material 12 used in the reactive composite linking process is typically nanostructured materials as described in US Pat. No. 6,534,194 B2 to Weis and his colleagues. The reactive composites 12 are typically vapors of hundreds of layers of nano-scale layers that alternate between components with large negative heats of mixing, such as nickel and aluminum. It is made by vapor depositing. It has been found in recent developments that it is possible to carefully control both the heat of reaction as well as the rate of reaction by varying the thickness of the alternating layers. It has also been found that the heat of reaction can be controlled by modifying the composition of the thin film or by low-temperature annealing after the preparation of the reactive multilayer structures. It is also known that other methods for making nanostructured reactive multilayers include mechanical processing.

Two major advantages achieved by the use of reactive composites for the connection of components are the localization of heat to the speed and the connection area. The increased speed and localization are advantageous over applications with components that have large differences in coefficient of thermal expansion, such as temperature-sensitive components or metal / ceramic bonds, in particular over conventional soldering or soldering methods. In conventional welding or soldering, temperature-sensitive components can be destroyed or damaged during the process. Residual thermal stress in the components can require costly and time consuming tasks such as subsequent annealing or heat treatment. In contrast, the connection to reactive composites causes the components to be less heated and only cause a very local temperature rise. In general, only adjacent fusible layers and the connecting surfaces of the components are substantially heated. Thus, the risk of thermal damage to the components is minimized. In addition, reactive composite connections result in fast and cost-effective, strong and thermally conductive connections.

Although conventional reactive composite connections work well in the connection of components to areas up to about 4 inches in length and up to about 16 square inches, there are particular difficulties with connections to larger lengths and areas. For optimal connection it has been observed that the surfaces to be joined are heated uniformly and as simultaneously as possible. As these lengths and areas become larger, the difficulty in maintaining the desired reaction concurrency and uniformity from a single flash point also increases. In addition, larger connection area sizes can exceed the sizes of the easily produced reactive composites, requiring multiple pieces of reactive thin film to cover all of the connection surface areas. Even when the linking reaction develops rapidly through the reactive composite material, not all parts of the large surface area linking region can be melted at the same time, which can result in poor bonding between the components. . Moreover, the increase in the surface area to be connected leads to an increase in stringent requirements of the application of uniform pressure to the components during the connection process.

Thus, it would be advantageous to provide a reactive composite linking process for use in connecting to a surface area larger than the size of the reactive composite of a single sheet, which results in a strong and relatively uniform bond between the component materials. Bring it.

Summary of the Invention

Briefly stated, the present invention relates to a method of connecting the body of component material over large areas by placing a plurality of substantially contiguous reactive composite sheets between the body of component material. to provide. Substantially contiguous sheets of reactive composite material are bonded to at least one adjacent sheet of reactive composite material by a bridging material capable of transferring an energetic reaction from one sheet to another sheet. do. As a result of rapid localized heating of materials adjacent to the sheets, enabling ignition reactions to initiate within one or more of the sheets of reactive composite material and to diffuse through all remaining sheets via the crosslinked material To form a bond between the bodies of the component material by cooling.

In one embodiment of the present invention, the plurality of substantially contiguous reactive composite sheet sheets located between the component material bodies to be connected over a large area are bonded to each other by a crosslinking material. The crosslinking material may be in the form of a reactive thin film, reactive wire, reactive layer, reactive powder, or may be another material capable of transferring an ignition reaction from one sheet to another, directly or by thermal conduction. . The crosslinked material reacts in response to the ignition of the first reactive composite material sheet to ignite the second reactive composite material sheet.

In another embodiment of the present invention, the plurality of substantially contiguous reactive composite sheets positioned between the component material bodies to be connected over a large area are supported by structural support tabs of the fusible material. It is possible to easily assemble, transport and position multiple reactive composite sheets between the component bodies to be coupled and connected to each other.

In a variant of the invention, the plurality of substantially contiguous reactive composite sheets are positioned directly adjacent the surfaces of the component material bodies to be connected between the component material bodies to be connected over a large area.

In another embodiment of the present invention, a plurality of substantially contiguous sheets of reactive composite material are positioned between component material bodies to be connected over a large area. Sheets of fusible material, such as solder or brass, are located in the reactive composite sheets and adjacent the component material bodies. The fusible sheets are overlie, underlie, or sandwiched between the reactive composite sheets. The fusible sheets can be continuous across the boundaries of the connecting reactive composite sheets, and can optionally function as a connecting material to secure the reactive composite sheets to each other.

The method of the present invention for joining bodies of component material over a large area places at least one sheet of reactive composite material between the component material bodies. The ignition reaction is initiated at a plurality of ignition points positioned relative to the reactive composite material sheet, resulting in rapid localized heating of the materials adjacent to the sheets, thereby bonding between the bodies of the component material by cooling. To be formed.

A variant of the method of the present invention for joining bodies of component material over a large area places at least one sheet of reactive composite material between the component material bodies. At least one spacer plate is located between the external pressurization source and the component bodies. Pressure is applied to the array from an external pressure source to cause the component bodies to be clamped against each other so that the coupling between the component bodies subsequent to initiation of the ignition reaction in the reactive composite sheets Control formation. The ignition reaction in the reactive composite sheets results in rapid localized heating of the materials adjacent the sheets, which form a bond between the bodies of the component material by cooling.

Advantages, attributes and various additional features of the present invention will become more fully apparent in view of the illustrative embodiments that will be described in detail with reference to the accompanying drawings.

1 conceptually illustrates the arrangement of the prior art for carrying out a typical reactive complex linkage of two components.

2 is a block diagram illustrating the steps involved in connecting two bodies by massive connection in accordance with the present invention.

FIG. 3 is a plan view of a number of contiguous reactive composite sheets that are operably connected by structural support tabs and ignition bridges in a bonding region for the formation of large scale bonds between two components; FIG. to be.

4 shows a number of contiguous reactive composites operably connected by structural support tabs in a joining region and ignition bridges external to the joining region for the formation of large scale bonds between two components. Top view of material sheets.

FIG. 5 is a diagrammatic representation of several contiguous sheets of reactive composite material operably connected by ignition bridges external to the bonding area for the development of the ignition reaction from sheet to sheet.

FIG. 6 is a cross-sectional view of a pair of contiguous reactive composite sheets sandwiched between two fusible layers. FIG.

7 is a block diagram showing the arrangement of components and layers for implementing the connection method of the present invention.

8 shows an exemplary arrangement for simultaneous ignition of multiple reactive composite sheets during formation of a bonding point in accordance with the present invention.

9 is a planar acoustic image of a large scale connection formed in accordance with the method of the present invention.

10 is a planar acoustic image of a large scale connection formed in accordance with the method of the present invention, showing edge voids.

11 is a planar acoustic image of a large scale connection formed according to the optimized loading bonding method of the present invention.

FIG. 12 illustrates an exemplary arrangement of contiguous reactive composite sheets, fusible support tabs, ignition bridges, and ignition points.

FIG. 13 is a planar acoustic image of a large scale connection resulting from the arrangement shown in FIG. 12.

FIG. 14 illustrates an exemplary arrangement of contiguous reactive composite sheets, fusible support tabs, ignition bridges, and ignition points.

FIG. 15 is a planar acoustic image of a large scale connection resulting from the arrangement shown in FIG. 14.

16 is a block diagram illustrating a first exemplary arrangement of components and layers for carrying out the connection method of the present invention.

17 is a block diagram illustrating a second exemplary arrangement of components and layers for implementing the connection method of the present invention.

Corresponding reference numerals indicate corresponding parts throughout the several numbers of the drawings. It is to be understood that the drawings are intended to illustrate concepts of the invention and are not to be accumulated.

Best mode for carrying out the invention

The following detailed description is intended to illustrate the invention by way of example, and not to limit it. The following detailed description enables the manufacture and use of the invention by those skilled in the art, including what is presently considered the best mode of practice of the invention, and in various embodiments, applications , Variations, alternatives, and uses of the present invention are described.

As used herein, the term "large dimention" is used to describe the joining or bonding area and exceeds the area or length of a single sheet of reactive composite utilized in the joining processes. It is understood that it refers to a connection or bonding region having an area or length, which means that a single wave front from the ignition reaction in one sheet of reactive composite material provides the desired bonding properties through the bonding region. It is meant to be large enough to fail to achieve or to indicate a loading variation between the center and the corners of the connection or coupling region. For example, if one sheet of reactive composite material having an area of 16 square inches or less and a longest dimension of 4 inches or less is utilized, an area of at least 16 square inches or a length of at least 4 inches is large. It is considered to be.

As used herein, "reactive composite material" or "RCM" is controlled by a person skilled in the art such as appropriate excitation or exothermic reaction initation or the like. It is understood that by means of the method is meant a structure comprising phases of two or more materials sequestered in a controlled method such that the materials carry out an exothermic chemical reaction which diffuses through the composite structure. These exothermic reactions result in electrical resistance heating, inductive heating, laser pulses, microwave energy or ultrasonic disturbances of the reactive composite at one or more ignition points. It may be initiated by (ultrasonic agitation).

Referring to the drawings, FIG. 2 illustrates two component bodies 10A, 10B with each other over a connecting or bonding area having a large (wide area or long length) using at least two contiguous sheets 12 of a reactive composite material. A generalized flow chart of the steps involved in connecting is shown. First, as shown in block A, two components 10A, 10B are provided that will be connected across substantially matching large mating surfaces. The two component bodies 10A, 10B are previously coated with one or more layers of the fusible material 14A, 14B, such as solder or brass alloy, or one or more of the fusible materials 14A, 14B. The above sheets may be located between the component bodies 10A and 10B. The component bodies 10A, 10B may comprise the same type of material, such as brass, or nickel and brass, aluminum and titanium, boron carbide and steel, boron carbide and copper, silicon carbide and aluminum And different types of materials such as tungsten-titanium alloy and copper-chromium alloy.

Next, as shown in block B, two or more sheets of reactive composite material 12 in a substantially contiguous arrangement are positioned between the mating surfaces of the two component bodies 10A, 10B. . As used herein, the term "contiguous" means that any adjacent edges of the sheets 12 of the reactive composite material are substantially void-free by those skilled in the art. free close to each other as necessary to form a bond and adjacent sheets 12 of the reactive composite material are arranged close enough to each other so that they can be operated in a single assembly and connected to each other. I understand. The sheets of contiguous reactive composite material need not be in physical contact with each other.

In order to operatively connect adjacent reactive composite sheet 12, a number of structurally supporting bridges or tabs 20 (as shown in FIGS. 3 and 4) are described above. It is formed between the sheets 12. The bridges or tabs are formed from both fusible material 20, which may form part of the bond between the component bodies 10A, 10B, or ignite between adjacent sheets of reactive composite material. It may be formed from a reactive material 22 capable of delivering. Using the bridge or tabs, two or more adjacent reactive composite sheets 12 are assembled and transported between the mating surfaces of the component bodies 10A and 10B within the large-scale bonding zone. And fixed to one another in one assembly in such a way as to maintain positions relative to one another during positioning.

Structural support bridges or tabs 20 may be any one of several forms for securing the reactive composite sheet 12 in contact with each other in the assembly 24. In one exemplary embodiment, the structural support bridges or tabs 20 may be in the form of a soft metal or fusible sheet, for example indium, which is the reactive composite sheet 12. It is cold pressed or rolled onto the field.

The ignition bridge or tab 22 formed from the reactive material is preferably such that it enables any of the conduction of ignition or thermal energy between the adjacent sheets 12 so that the bridge or It is selected in such a way that it is possible to allow the reactions disclosed to the adjacent sheet 12B to continue via the tab. The shape of the ignition bridge or tab 22 can be any one of a number of shapes that assist in the development of the reaction between the connecting sheets of reactive composite material 12. For example, the ignition bridge or tab 22 includes regions or layers of materials having a reactive negative thin film or a large negative mixed heat similar or identical to that used for the reactive composite sheet 112. It can be in the form of a thin wire. These shapes of the ignition bridge or tabs 22 may be attached to either or both of the sheets 12 to be joined with a small amount of glue or a small amount of fusible solder. In addition to delivering the disclosed reactions, the ignition bridge or tabs 22 may be configured to provide structural support of the structural, that is, structural, arrangement of the sheets 12 of the reactive composite material, or may be non-structurally supported. . For example, the non-structurally supporting ignitable bridge 22 may be in the form of a loose or dense powder mixture of materials with a large negative heat of mixing.

Advantageously, the various shapes of the bridges and tabs 20, 22 are small compared to the size of the reactive composite sheet 12 and the flow of any fusible material present in the bonding zone or the configuration during the connection process. It does not interfere with the flatness of mating surfaces of the element body.

Referring again to FIG. 3, disposed and connected by solder assembly tabs 20 and ignitable bridges 22 to cover a large engagement area 26 between two component bodies (not shown). An exemplary arrangement of a plurality of contiguous reactive composite sheet 12 forming reactive composite sheet assembly 24 is shown. In the arrangement shown in FIG. 3, both the solder assembly tabs 20 and the ignitable bridges 22 are contained within the large area of engagement 26. Arrows arranged around the periphery of the assembly 24 indicate a plurality of ignition or reaction initiations associated with the assembly 24.

4 is a sheet of reactive composite material disposed and connected by solder assembly tabs 20 and ignitable bridges 22 to cover a large bond area 26 between two component bodies (not shown). A second exemplary arrangement of multiple contiguous reactive composite sheet 12 forming assembly 24 is shown. In the arrangement shown in FIG. 4, the solder assembly tabs 20 are included in the large engagement zone 26, while the ignitable bridges 22 are located outside the large engagement zone 26. By placing the ignitable bridges 22 outside of the large engagement zone 26, the ignitable bridges 22 are assembled by tape or other means not possible within the large engagement zone 26. And may be attached to the sheets 12 of 24. Thus, as indicated by the arrows disposed around the periphery of the assembly 24 to indicate a plurality of ignition or reaction initiation points, the same within the assembly 24 as for igniting the coupling regions. It can be used as for fixing the sheets 12.

Within the large bond area 26, the solder tabs 20 may be secured to the sheets 12 of the assembly 24 by pressing or with a small amount of adhesive. If it is not desirable to use solder material other than the solder material used as fusible material in the connection as the tab 20 due to concerns with alloying, then the small tabs of the desired solder may be The reactive sheets can preferably be attached with a minimum amount of adhesive.

5 shows a reactive composite disposed and connected by solder assembly tabs 20 and ignitable bridges 22 to cover a large linear engagement region 30 between two component bodies (not shown). A third exemplary arrangement of a plurality of contiguous reactive composite sheet 12 forming material sheet assembly 24 is shown. The ignitable bridges 22 may be attached to the reactive sheets 12 with small pieces of adhesive or solder material if they are located in a joint region, and if they are located outside the joint region. It can be attached with an adhesive tape.

Those skilled in the art will appreciate the various assemblies 24 shown in FIGS. 3, 4 and 5 depending on the size and arrangement of the large area 26 or the large linear area 30. It will be appreciated that a number of reactive composite material sheets 12 may be modified. Preferably, the reactive composite sheet 12 is as far from the interior of the bonding region as possible with a gap G between adjacent sheets 12, in particular a gap G parallel to the edges of the bonding region. It is disposed in the assembly 24 in such a way as to lose. Similarly, it is assumed that the assembly 24 is held in a stable arrangement while the assembly 24 is located in the bonding zone and reactions can develop in a generally fast and uniform manner between the sheets 12 of the assembly 24. It will be appreciated that the placement and number of tabs 20 and ignition bridges 22 may vary depending upon the particular application and the shape of the assembly 24.

Instead of assembly tabs 20, an assembly 24 of two or more reactive composite sheets 12 into the ignition bridge 22 is a fusible material such as solder or brass as shown in FIG. 6. It may be a package (encapsulate) between the layers (32A, 32B) of. This packaging allows the assembly 24 of the fusible layers 32A and 32B and the reactive composite sheet 12 to be treated as a unit and placed within a bonding area. To help. The reactive composite sheet 12 is bonded to the fusible layers 32A and 32B by rolling, pressing or other suitable means to ensure that the packaging is structurally fixed. Can be.

Once the assembly 24 is formed with or without fusible layers 32A and 34B, it is located in the bonding region 26 between the components 10A and 10B to be connected. As shown in block C of FIG. 2, the components 10A, 10B to be connected to each other are pressed against each other to provide a generally uniform pressure over the engagement region 26. For example, various mechanisms and methods, such as hydraulic presses or mechanical presses, may be utilized to provide a generally uniform over the joining area 26 between the components 10A and 10B. Pressure can be achieved. As shown in FIG. 7, the components 10A and 10B may be located with appropriate spacers 34 between a pair of platens 36A and 36B. The selection of the spacers 34 and, consequently, the effect on the bonding formed in the bonding region 26 will be described in detail below. An optional compliant layer 38, such as a rubber sheet, is placed in the component arrangement between one component 10A or 10B and an adjacent pressurizer platen and configured during the connection process. It is possible to compensate for any imperfections on the outer surfaces of the elements 10A, 10B and the surfaces of the presser platens 36A, 36B. Pressure is applied to the pressurizer platens 36A, 36B by any suitable means, such as by means of a hydraulic presser capable of automatic pressure control.

As shown in block D of FIG. 2, the final step is to ignite the reactive composite sheet 12 comprising the assembly 24. When combining large areas, the reactive composite sheet 12 is symmetrically ignited at various points around the perimeter edge of the assembly 24, as indicated by the firing point arrows in FIGS. 3 and 4. It is advantageous to. Subsequently, inner sheets 12 having no outer edges of the engaging region 26 are ignited by the development of the reaction across the ignition bridges 22 in the assembly 24 as described above. Simultaneous ignition of the sheets 12 in the assembly 24 may be achieved by simultaneous application of electrical impulse or laser impulse, induction, microwave as shown in FIG. 8. It may be conveniently exerted by microwave radiation or ultrasonic energy.

It will be appreciated by those skilled in the art that a variety of mechanisms capable of simultaneous transmission of ignition energy to the ignition points can be used. For example, an electrical circuit consisting of a capacitor and a switch associated with each ignition point may be used. The switches are all controlled by one master switch in such a way that the capacitors charge and discharge simultaneously. An electrical pulse travels from the capacitor to the ignition points on the reactive composite sheet 12 through the switch and through the platens 36A and 36B to electrical ground. Ignite the sheets 12 in and ultimately form a bond between the components 10A, 10B. Alternatively, a single large capacity capacitor and switch are connected in parallel to all of the ignition points such that energy is discharged from the capacitor to all ignition points around the assembly 24 simultaneously to ignite each sheet 12. You can do that.

During the joining process, a non-uniform load distribution between the component bodies 10A, 10B following air ignition of the sheets 12 in the assembly 24 results in air gaps. It can result in a low quality combination where voids are present. Non-uniform load distribution typically occurs when the pressurizer platens 36A, 36B of the loading mechanism are obviously much larger or smaller than the size of the engagement region 26. This problem may be exacerbated when one or more of the components 10A, 10B to be connected are relatively thin. When the pressurizer platens 36A and 36B are larger than the size of the coupling zone 26, the pressure near the edge of the peripheral edge of the coupling zone 26 is greater than the pressure near the center of the coupling zone 26. This results in the formation of voids near the center of the coupling region 26. This is represented by the planar ultrasound image of the coupling region 26 shown in FIG. 9 or the white regions visible near the center of the C-scan.

Conversely, when the pressurizer platens 36A, 36B are smaller than the engagement zone 26, the pressure near the center of the engagement zone 26 is greater than the pressure near the periphery edge of the engagement zone 26. The pores may appear around the periphery edges as they are larger and thus appear as planar ultrasound images of the coupling region 26 shown in FIG. 10 or as white areas visible near the periphery edges of the sea-scan.

In order to distribute the load from the pressurizer platens 36A and 36B to the engaging region 26 in a uniform manner, one or more spacer plates 34 having a size corresponding to the engaging region 26 are provided. Located between components 10A and 10B and the platens or platens 36A and 36B. The ideal thickness for the spacer plate or spacer plates 34 can be determined by sequential processes, where a test bond is initially formed without the use of any spacer plate or spacer plates 34. . The bond between the resulting components 10A, 10B is evaluated to confirm the presence of voids. For applications in which the presser platens 36A, 36B are larger than the joining region 26, the quality of the joining is cavitation in the central quarter of the joining region 26 over the entire area of the joining region. It can be characterized by the proportion of voided area. In order to reduce the cavitation area, it is increasingly increased between components 10A and 10B in separate bonding test procedures until a desired ratio of cavitation areas to bonding area is achieved for the bonding process. Spacer plates 34 of thickness are used. Preferably, the thickness of the spacer plate 34 is doubled between each bonding test procedure until the desired ratio is achieved.

The procedure can be modified for large scale connection applications where there are no edge voids or only a limited number of corner voids are allowed. For these applications, the percentage of edge voids as defined as the ratio of the cavitation area within one quarter of the engagement area 26 to the total connection area can be pursued as described above. If the process of doubling the thickness of the spacer plate yields an acceptable percentage of center voids and the absence of edge voids (none), the thickness of the plate is obtained. On the other hand, if the process results in the detection of a small percentage of edge voids while within an acceptable percentage of the central voids, the thickness of the spacer plate is the average of the thicknesses of the spacer plate and the spacer plates above. It must be reduced in thickness. This process is repeated until the spacer plate 34 with the desired thickness results in the minimum amount of center voids and the desired amount of corner voids. The planar ultrasonic acoustic image of the coupling region 26 shown in FIG. 11 or a small white region near the center of the sea-scan and any absence of any white regions visible near the peripheral edges.

For applications in which the presser platens 36A and 36B are smaller than the joining region 26, the ratio of the cavitation area in the outer quarter of the joining region 26 to the total area of the joining region is as a ratio. The bond quality can be characterized. In order to reduce the cavitation area, increasing thickness between components 10A and 10B in separate bonding test procedures until a desired ratio of cavitation areas to bonding area for the bonding process is achieved. Spacer plates 34 are used. Preferably, the thickness of the spacer plate 34 is doubled between each bonding test procedure until the desired ratio is achieved.

The methods of the present invention for connecting components 10A and 10B over large coupling area 26 are further described in the following six embodiments.

Example 1

In this embodiment, reactive or ignition bridges 22 and assembly tabs 20 were positioned on the assembly 24 inside the perimeter edges of the engagement region 26 as shown in FIG. 3. As shown in the general arrangement of FIG. 7, the joints 26 are to be formed between the nickel disk component 10A (0.2 inch thick) and the brass disk component 10B (0.6 inch thick). Was assembled between the pressurizer platens 36A and 36B. The joining region 26 is circular with an outer diameter of 17.7 inches and an area of 246 square inches (in ² ). Layers of fusible material 32A, 32B, such as tin-lead solder, have been pre-applied to the nickel and brass component bodies 10A, 10B. In order to provide coverage (coverage) for the bonding region 26, 12 indium solder tabs across the gap G as an assembly 24 as shown in FIG. 3 ( By pressing all 20), 16 reactive composite sheet 12 (nickel-aluminum, 80 mu m, reaction rate 7 m / s) were preassembled. In order to ensure reaction evolution across the gaps G, six reactive foil ignition bridges 22 were attached across the gap G in the bonding region 26. . Small pieces of indium solder were additionally used to attach the reactive thin film ignition bridges 22 to the reactive composite sheet 12.

The brass disk component 10B was placed on a flat surface for the pre-applied layer of tin-lead solder 32B facing upwards. The parts of the assembly 24 were placed adjacent to each other with a minimum separation gap G on the top of the brass disk 10B so that they completely covered the coupling area 26. Tin-lead solder 32A facing down by bringing the nickel disk 10A into contact with the reactive composite material (nickel-aluminum, 80 μm, reaction rate 7 m / s) 12 in the assembly 24. ) Was applied over the reactive multilayer thin film for the pre-applied layer. One aluminum spacer plate 34 having a thickness of 0.75 inches and a diameter of 17.7 inches was positioned above and aligned with the nickel disk 10A. The spacer thickness was predetermined using the process described above by making several connections to spacer plates having different sizes. A thin layer of hard rubber 38 having a matching surface area is placed over the aluminum spacer plate 34 to load the outer surfaces of the brass and nickel disks 10A, 10B and during the connection. Any non-uniformity on the surfaces of the platens 36A, 36B of the pressurizer used to apply was made to accommodate. The entire batch was transferred to a hydraulic pressurizer where a load of 107,000 pounds (lbs) was applied to the batch. Subsequently, the seats 12 of the assembly 24 were electrically and simultaneously ignited at twelve ignition points around the periphery indicated by arrows in FIG. 3, and the component bodies 10A, 10B were ignited. Resulted in bonding to each other.

Example 2

In this embodiment, as shown in FIG. 4, the assembly tabs 20 are positioned on the assembly 24 inside the periphery edges of the joining region 26 while the reactive or ignition bridges 22 are removed. The periphery edges of the engagement zone 26 were located outward. As shown in the general arrangement of FIG. 7, the various components form a joining region 26 to be formed between nickel disk component 10A (0.2 inch thick) and brass disk component 10B (0.6 inch thick). With presser platens 36A and 36B. The joining region 26 is circular with an outer diameter of 17.7 inches and an area of 246 square inches. As with Example 1 above, layers 32A, 32B of fusible material, such as tin-lead solder, were pre-applied to the nickel and brass component bodies 10A, 10B. In order to provide coverage for the bonding area 26, eight of the three indium solder tabs 20 are pressed across the gap G as an assembly 24 as shown in FIG. Reactive composite material sheets 12 were preassembled. In order to ensure reaction evolution across the gaps G, eight reactive thin film ignition bridges 22 were attached across the gap G outside the bonding region 26. High temperature tape; bit of the (high temperature tape Kapton ^® (Kapton ^®)) have been used provide adhesion between the ignition bridge (22) and the reactive composite material sheet 12 and the structure of geurigeo the assembly 24 It was to function more for the purpose of providing support.

Next, the brass disk component 10B was placed on a flat surface for the pre-applied layer of tin-lead solder 32B facing upwards. The parts of the assembly 24 were placed adjacent to each other with a minimum separation gap G on the top of the brass disk 10B so that they completely covered the coupling area 26. The nickel disk 10A was applied over the reactive multilayer thin film to the pre-applied layer of tin-lead solder 32A facing down in contact with the reactive composite materials 12 in the assembly 24. One aluminum spacer plate 34 having a thickness of 0.75 inches and a diameter of 17.7 inches was positioned above and aligned with the nickel disk 10A. The spacer thickness was predetermined using the process described above by making several connections to spacer plates having different sizes. A thin layer of hard rubber 38 having a matching surface area is placed on the aluminum spacer plate 34 to allow the outer surfaces of the brass and nickel disks 10A and 10B to be used to apply a load during connection with the outer surfaces of the brass and nickel disks 10A and 10B. Any irregularities on the surfaces of the platens 36A and 36B were to be accommodated. The entire batch was transferred to a hydraulic press and a load of 107,000 pounds was applied to the batch. Subsequently, the seats 12 of the assembly 24 were electrically and simultaneously ignited at 16 ignition points around the periphery indicated by arrows in FIG. 4, and the component bodies 10A, 10B were ignited. Resulted in bonding to each other.

Example 3

In this embodiment, as shown in FIG. 12, the assembly tabs 20 and the ignition bridges 22 are both located on the assembly 24 at both the inside and outside of the peripheral edges of the engagement region 26. I was. According to the general arrangement shown in FIG. 7, the component bodies 10A, 10B consisting of 0.3 inch (0.3 ") thick copper alloy discs 10A and 0.5 inch thick copper alloy discs 10B are formed in the joining region 26. The bond zone 26 is circular, having an outer diameter of 13 inches and an area of 133 square inches, in which the tin-lead solder is made of fusible layers 32A and 32B. Nine reactive composite sheets 12 were preassembled in the assembly arrangement 24 shown in FIG. 12 by pressing four indium solder tabs 20 across the sheet spacings G. FIG. In order to ensure reaction evolution across the gaps G, ten reactive ignition bridges 22 are placed at critical boundaries, two within the bonding region 26 and eight above. It was attached to the outer side of the joining area 26. Shown in FIG. As shown, a 0.5 inch copper disk 10B is at the bottom but without the optional spacer plate 34 thereunder, and subsequently the assembly 24 is placed within the joining region 26 and subsequently 0.3 inch. Several components were placed to position the copper disk 10A on top.A single aluminum spacer plate 34 was positioned over and aligned with the 0.3 inch thick copper disk 10A. A foam functioned as the compliant layer 78. The entire batch was transferred to a hydraulic pressurizer where a 57,850 pound load was applied to the assembly 24 by the pressurizer. The sheets 12 are electrically drawn at twelve points evenly spaced around the periphery as indicated by the arrows in FIG. 12. It was ever ignition was initiated by the bond formation reaction.

The resulting connected assembly was scanned ultrasonically (acoustically) to determine the quality of the bond. A representative acoustic scan with regions of poor bonding quality including trapped air known as voids appearing as bright white regions adjacent to the peripheral edges of the bonding region 26 is shown in FIG. 13. The void content, measured as a percentage of the total bonding area, indicates a high quality bond of less than or equal to 1%. The black lines in FIG. 13 indicate cracks or gaps between the individual sheets of reactive composite material filled by molten solder during the connection process. The straight black lines are due to the cracking of the individual sheets of the reactive composite material which occurs due to the volume shrinkage of the sheets as the reactive composite sheets react during the connection. The gaps filled between the individual pieces of the reactive multilayer thin film are straight lines and represent a pattern of individual sheets of the reactive composite material preassembled into the assembly 24 prior to bonding.

Example 4

In this embodiment, as shown in FIG. 14, the assembly 24 of the reactive composite sheet 12 is in combination with the assembly tabs 20 located within the rectangular joining region 26 and the rectangular joining region. It was arranged with the ignition bridges 22 on the outside of the peripheral edges of (26). The components 10A, 10B to be joined consist of a square plate 10A of 0.5 inch thick aluminum and a square plate 10B of a titanium-aluminum-vanadium alloy of 0.5 inch thick. The joining area 26 defines a rectangle having a side length of 12 inches and an area of 144 square inches. Tin-silver solder was used to provide fusible layers 32A and 32B on the two components 10A and 10B. Six equally sized sheets of reactive composite material 12 were preassembled in the pattern shown in FIG. 14 by pressing two indium solder tabs 20 across the gap G between the sheets 12. . In order to ensure reaction evolution across the gaps G, six reactive multilayer thin film ignition bridges 22 were attached to critical boundaries outside the bonding region 26. As shown in FIG. 7, a rectangular spacer plate 34 of aluminum 0.5 inch thick and 12 inch sides was placed on a flat surface. The titanium alloy component 10B, reactive multilayer thin film assembly 24 and aluminum component body 10A were then placed on top of the spacer plate 34. A second rectangular aluminum spacer plate 34 of the same dimensions as the first spacer plate was positioned on and aligned with the aluminum component body 10A. A thin layer of hard rubber was placed on the second spacer plate 34 to function as the compliant layer 38. The entire assembled batch was transferred to a hydraulic pressurizer where a load of 62,640 pounds was applied to the assembled batch by the pressurizer platens 36A and 36B. The reactive composite sheet 12 is electrically ignited simultaneously at ten evenly spaced points around it as indicated by the arrows in FIG. 14 to bond between the components 10A and 10B. Resulted in a reaction.

The quality of the coupling was determined by ultrasonically scanning the connections between the resulting component bodies 10A, 10B. Acoustic wave scanning is shown in FIG. 15. The pore content, measured as a percentage of the total bonding area, indicates a high quality bond of 1% or less. The black horizontal and vertical lines in FIG. 15 represent the gaps between the individual sheets of reactive composite material filled by the molten solder during the connection process. Thus it could be clearly observed from the ultrasonic sea-scan that six sheets of reactive composite material effectively connect the two component bodies 10A, 10B.

Example 5

In this embodiment, the assembly 24 of the reactive composite sheet 12 is simultaneous of a set of discrete component tiles 40A to 40F as systematically shown in FIG. 16. It was used for the connection. The discrete component tiles 40A to 40F are made of boron carbide (B ₄ C) and have dimensions of 6.25 inches long, 6 inches wide and 0.25 inches thick. 42 includes a copper plate having a total dimensions of 26.25 inches long, 7.25 inches wide and 0.31 inch thick, the joining area 26 being 25 inches long, 6 inches wide and 150 cubic inches. It has a rectangular shape of area The layers of tin-silver solder pre-applied to the copper plate 42 and the individual boron carbide tiles 40A to 40F act as fusible layers 32A and 32B. As can be seen, the six reactive composite sheet 12 taping into ten reactive multilayer thin film ignition bridges 22 across the gaps between the sheets 12 outside of the bonding region 26; By bonding with tape) It was preassembled into one assembly 24 to increase the likelihood of simultaneous ignition of all of the sheets 12. The copper plate 42 was placed on a layer of tin-silver solder 32B facing upwards. The assembly 24 was placed on top of the copper plate 42 so as to completely cover the bonding area 26. Tin-silver solder 32A was layered down. Each boron carbide tile 40A to 40F is positioned above the assembly 24 in a desired arrangement such that it is in contact with the sheets 12 of the assembly 24. In this embodiment, the carbonization The boron tiles 40A to 40F were positioned in contact with each other from end to end as shown in Fig. 16 and aligned so as to align with the rectangular joining region 26. The shape of the joining region 26 coincides with each other. Tight and A thin, compliant layer 38 of radish was positioned over the boron carbide tiles 40A to 40F. An aluminum spacer plate 34 is located on the compliant layer 38 and the bonding region. It was sorted about 26. The entire batch was transferred to a hydraulic pressurizer where a load of 65,250 pounds was applied to the batch by the pressurizer platens 36A, 36B. The reactive composite sheet 12 is electrically and simultaneously ignited at twelve uniformly spaced points corresponding to each of the ignition bridges 22 and the ignition bridges at each end of the assembly 24. The result was a coupling reaction between the copper plate 42 and the boron carbide tiles 40A to 40F.

Example 6

In this embodiment, the assembly 24 of the reactive composite sheet 12 has non-planar (curved) surfaces facing the two curved component bodies 44A, 44B as shown in FIG. 17. It was used to bind phase. In particular, component body 44A comprising a curved steel sheet having a thickness of 0.015 inches was bonded to component body 44B comprising a curved boron carbide tile. The bonding area was not limited to a regular shape and had a surface area of approximately 111 square inches. Fusible layers 32A and 32B of tin-silver solder were pre-applied to the steel sheet and the boron carbide tile. By taping across and tapering the gaps G outside of the irregularly curved bond region 26 and pressing the two indium solder tabs across the gaps G inside the bond region 26. Two reactive multilayer thin film ignition bridges 22 were preassembled into the assembly 24. The boron carbide tiles were placed on a form-fitting mold 46 with the fusible layer 32B of tin-silver solder facing upwards. The shape-fitting mold 46 was padded with a compliant layer 38 of rubber to accommodate surface defects. Comprising four pieces of each 3-inch width-tin-titanium solder fusible layer which independently consisting of ^{(S-Bond ®) (free} -standing fusible layer) (48) is on said boron carbide tile (44B) Was located in. Subsequently, the reactive composite assembly 24 was placed on top of the independent fusible layer 48 to completely cover the irregularly curved bonding region 26. Tin-silver solder 32A was directed down so that the steel sheet 44A was positioned above the next assembly 24. A matching shape-fitting mold 50 was placed on top of the steel sheet 44A and the entire assembly was transferred to a hydraulic press. The presser platens 36A, 36B apply a load of 32,000 pounds to the assembly, and electrically ignite simultaneously at ten points spaced evenly around the perimeter edges of the engagement zone 26. The binding reaction was initiated through the curved irregular binding region.

Since various modifications may be made in the above configurations and procedures without departing from the scope of the invention, all configurations shown in the foregoing detailed description or the accompanying drawings are intended to be illustrative and are in scope of the invention. It is not constitutional.

The present invention provides a method of connecting powders of material on large scale bonding regions using reactive composite materials such as reactive multilayer foils and the like, and can be used in the production of such products.

Claims (50)

Positioning a sheet of at least one reactive composite material between the first component body and the respective additional component body; And Initiating an exothermic reaction in the sheet of reactive composite material resulting in the formation of a bond between the first component body and the at least one additional component body over a large area of bonding; And coupling the first component body to the at least one additional component body over a large engagement area. The method of claim 1, And wherein said large-scale bonding zone has a surface area greater than the surface area of one sheet of reactive composite material over at least one additional component body over a large-scale bonding zone. The method of claim 1, A first component body over a large bond area, wherein said large bond area has at least one corresponding specification that is greater than the size of one sheet of reactive composite material, and wherein said at least one size is a length or width. To the at least one additional component body. The method of claim 1, Applying a pressure on the sheet of at least one reactive composite material through the first component body and each additional component body, wherein the pressure causes the exothermic reaction and causes the exothermic reaction to occur. A method of joining a first component body to at least one additional component body over a large area of engagement characterized in that it is applied during. The method of claim 4, wherein Positioning at least one spacer plate in the vicinity of the component body prior to applying the pressure, wherein the spacer plate alters pore formation during bond formation. A method of coupling a component body to at least one additional component body. The method of claim 1, At least one addition of a first component body over a large bond area further comprising positioning a layer of fusible material between the first component body and the sheet of at least one reactive composite material. To a component body of the apparatus. The method of claim 1, Further comprising placing a layer of fusible material between each of the at least one reactive composite material sheet and each of the at least one additional component bodies. To the at least one additional component body. The method of claim 1, Embedding at least one layer of the reactive composite material between at least two layers of the fusible material prior to placing at least one layer of the reactive composite material between the first component body and the respective additional component body. Further comprising the step of: coupling the first component body to at least one additional component body over a large engagement area. The method of claim 1, Said positioning further comprises positioning a plurality of adjacent sheets of reactive composite material between said first component body and each additional component body, Wherein said exothermic reaction is initiated in each of said plurality of adjacent sheets. 18. A method of coupling a first component body to at least one additional component body over a large area of bonding. The method of claim 9, Coupling the first component body to at least one additional component body over a large bonding area, wherein the exothermic reaction in the sheets of a plurality of adjacent reactive composite materials is initiated substantially simultaneously. Way. The method of claim 9, Positioning at least one ignition bridge between the sheets of the plurality of adjacent reactive composite materials, wherein the ignition bridge transfers the disclosed exothermic reaction between the sheets of the adjacent reactive composite materials. A method of coupling a first component body to at least one additional component body over a large area of engagement. The method of claim 11, Wherein the ignition bridge comprises at least one of a reactive composite material, a multi-layered wire, a loose mixture of reactive compounds and a dense mixture of reactive compounds. Method of coupling to the component body. The method of claim 9, Securing each of the plurality of adjacent sheets of reactive composite material into an assembly of reactive composite materials, wherein the first component body is attached to at least one additional component body over a large bond area. How to combine. The method of claim 13, And securing at least one structural support tab between the plurality of adjacent sheets of reactive composite material, the first component body over at least one additional component body over a large bond area. How to bind to. The method of claim 14, And wherein said at least one structural support tab is made of a fusible material, wherein said first component body is coupled to at least one additional component body over a large area of engagement. The method of claim 14, Coupling the first component body to the at least one additional component body over a large bond area, wherein the at least one structural support tab transfers the disclosed exothermic reaction between the adjacent sheets of reactive composite material. How to let. The method of claim 13, Coupling the first edges of the first component body to at least one additional component body over a large area of bonding, further comprising the step of joining adjacent edges of adjacent sheets of reactive composite material to form the assembly. Way. The method of claim 17, And joining the first component body to at least one additional component body over a large bond area, wherein the mating edges are joined with an organic adhesive. The method of claim 17, And joining the first component body to at least one additional component body over a large bonding area, wherein the joining edges are joined by a fusible material. The method of claim 1, And wherein the exothermic reaction is initiated by an electrical current, coupling the first component body to at least one additional component body over a large coupling area. The method of claim 1, And wherein the exothermic reaction is initiated by electrical resistive heating, coupling the first component body to at least one additional component body over a large coupling area. The method of claim 1, And wherein the exothermic reaction is initiated with at least one laser pulse. A method of coupling a first component body to at least one additional component body over a large coupling area. The method of claim 1, And wherein said exothermic reaction is initiated by induction heating, said first component body being coupled to said at least one additional component body over a large area of bonding. The method of claim 1, And wherein said exothermic reaction is initiated by microwave energy, said first component body being coupled to at least one additional component body over a large area of bonding. The method of claim 1, And wherein said exothermic reaction is initiated by ultrasonic disturbances, said first component body being coupled to at least one additional component body over a large area of engagement. The method of claim 1, Initiating said exothermic reaction in said sheet of said at least one reactive composite material initiates said exothermic reaction simultaneously at a plurality of ignition points within said sheet of said at least one reactive composite material. A method of coupling a first component body to at least one additional component body over a large area of engagement. The method of claim 26, Wherein the exothermic reaction is developed in a substantially simultaneous chamber from outside of the large-scale coupling zone to the central zone, wherein the first component body is coupled to at least one additional component body over the large coupling zone. . A connection body formed between a first component body and at least one additional component body by the method of claim 1. And a remainder of at least two component bodies and a plurality of sheets of reactive composite material positioned within the bonding region between the at least two component bodies. The method of claim 29, And wherein the remaining portions of the plurality of sheets of the reactive composite material are separated by uniform intervals within the bonding region. The method of claim 29, And wherein the remaining portions of the plurality of sheets of the reactive composite material exhibit a substantially symmetrical reaction wavefront development from the outside of the bonding region to the central portion of the bonding region. Connecting at least one ignition bridge between each adjacent reactive composite sheet in the assembly; Providing an ignition passage between each of said plurality of reactive composite sheet; Initiating an exothermic reaction in a first sheet of reactive composite material in said assembly; And Performing the exothermic reaction between adjacent sheets of reactive composite material in the assembly over the ignition bridges; A method of initiating an exothermic reaction in an assembly of a plurality of reactive composite sheet, characterized in that it comprises a. The method of claim 32, The exothermic reaction is initiated in the first reactive composite material sheet from the ignition of the ignition bridge bonded to the first reactive composite material sheet. Way. The method of claim 32, Initiating an exothermic reaction in an assembly of a plurality of reactive composite sheets, each ignition bridge comprising at least one of a reactive composite material, a multilayer wire, a loose mixture of reactive compounds and a dense mixture of reactive compounds. How to let. The method of claim 32, Initiating the exothermic reaction comprises initiating the exothermic reaction substantially simultaneously within the plurality of sheets of the reactive composite material. To initiate the process. The method of claim 32, Initiating the exothermic reaction comprises initiating the exothermic reaction substantially simultaneously at a plurality of points within a sheet of the reactive composite material. To initiate an exothermic reaction in And at least two adjacent sheets of reactive composite material connected by at least one coupling means. The method of claim 37, wherein And said coupling means is a structural support tab. The method of claim 38, And said structural support tab is made of a fusible material. The method of claim 37, wherein Wherein said bonding means comprises sheets of at least two adjacent reactive composite materials connected by at least one bonding means, arranged to transfer the disclosed exothermic reaction between said sheets of adjacent reactive composite material. Characterized in that the assembly. The method of claim 37, wherein And said joining means is a bond between abutting edges of said adjacent sheets of reactive composite material. 42. The method of claim 41 wherein Assembly wherein the bond is formed of an organic adhesive. 42. The method of claim 41 wherein Wherein said bond comprises a soluble material. A bonded structure, which is produced by the method of claim 1. The method of claim 44, And said large-scale joining area has an area larger than 16 square inches. The method of claim 44, And said large-scale bonding zone has a length greater than 4 inches. Positioning at least one sheet of reactive composite material between the first component body and the individual additional component bodies; And The exothermic reaction resulting in the formation of a bond between the first component body and the at least one additional component body over a large area of bonding results in a sheet of the reactive composite material at a plurality of ignition points on the sheet. Simultaneously initiating an exothermic reaction in the body; And coupling the first component body to the at least one additional component body over a large engagement area. Positioning at least one sheet of reactive composite material between the first component body and the individual additional component bodies; Positioning at least one spacer plate between at least one of said component bodies and an external pressure source; Applying pressure to the large-scale coupling zone from the external pressure source; And Initiating an exothermic reaction in the sheet of reactive composite resulting in the formation of a bond between the first component body and the at least one additional component body over a large area of bonding. ; And coupling the first component body to the at least one additional component body over a large engagement area. 49. The method of claim 48 wherein Wherein at least one spacer plate is selected to alter the nature of said coupling. The method of claim 1, wherein the first component body is coupled to at least one additional component body over a large area of engagement. The method of claim 49, And wherein said at least one spacer plate is selected to alter the distribution of voids in said bond. 1. A method of coupling a first component body to at least one additional component body over a large bonding area.

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